| Foamable composition and method for making a foam material therefrom, and an architectural material made from the foam material -> Monitor Keywords |
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  Foamable composition and method for making a foam material therefrom, and an architectural material made from the foam materialRelated Patent Categories: Synthetic Resins Or Natural Rubbers -- Part Of The Class 520 Series, Synthetic Resins Or Natural Rubbers, Ion-exchange Polymer Or Process Of Preparing, Cellular Product Formation Prior To Or During Solid Polymer Formation In The Presence Of A Stated Ingredient Other Than WaterThe Patent Description & Claims data below is from USPTO Patent Application 20070265363. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates to a foamable composition, more particularly to a foamable composition including a plastic material, coal ash, and a foaming agent, and to a method for making a foam material and an architectural material made from the foam material. [0003] 2. Description of the Related Art [0004] At present, architectural materials, such as slats, upper and lower beams, a control rod, and interlocking elements of a ventilation louver or Venetian blind, are made from a plastic material, such as polyvinyl chloride (PVC). During the manufacture of such architectural materials, particles of the plastic material are mixed with an additive, such as a stabilizer, a foaming agent, a lubricant, a processing aid, a filler, a colorant, or mixtures thereof, so as to form a pre-mixture. The pre-mixture is subsequently granulated and extruded into the plastic material having a desired shape. [0005] Although the plastic material has good processability, its manufacture, recycling or combustion tends to result in formation of poisonous gases. Especially, hydrogen chloride gas or dioxins are generated during PVC combustion. In order to avoid the environment from being polluted with the poisonous gases formed during combustion of the plastic material, it has been proposed to replace a portion of the plastic material with wood powders for manufacturing different parts of a ventilation louver or a venetian blind. However, the wood powders are expensive. In addition, extensive use of wood powders tends to result in deforestation, which is another kind of environmental concern. [0006] Chinese patent publication CN 1047272A has proposed a plastic composite made from a composition essentially consisting of waste polyvinyl chloride and coal ash. The plastic composite thus made is merely suitable for structural materials for concrete and asphalt construction. [0007] Therefore, there is still a need in the art to provide an economically and environmentally protective material that is suitable for the manufacture of slats, upper and lower beams, a control rod, and interlocking elements of a ventilation louver or Venetian blind. SUMMARY OF THE INVENTION [0008] Therefore, the object of the present invention is to provide a foamable composition and a method for making a foam material from the foamable composition, thereby providing an economical and environmentally protective material suitable for an architectural material, especially the architectural material for manufacturing parts of a ventilation louver, a Venetian blind or other hardware. [0009] According to one aspect of this invention, a foamable composition includes 100 parts by weight of a plastic material, 4 to 125 parts by weight of coal ash, and a foaming agent. [0010] According to another aspect of this invention, a method for making a foam material includes mixing 100 parts by weight of a plastic material with 95 to 105 parts by weight of coal ash and a foaming agent so as to form a foamable material, granulating the foamable material, and extruding and foaming the foamable material. [0011] According to yet another aspect of this invention, an architectural material is made from a foam material, wherein the foam material is made by mixing 100 parts by weight of a plastic material with 95 to 105 parts by weight of coal ash and a foaming agent so as to form a foamable material, granulating the foamable material, and extruding and foaming the foamable material. BRIEF DESCRIPTION OF THE DRAWINGS [0012] Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiment of this invention, with reference to the accompanying drawings, in which: [0013] FIG. 1 is a perspective view to illustrate a Venetian blind made from the preferred embodiment of a foam material according to this invention; and [0014] FIG. 2 is a perspective view to illustrate a ventilation louver made from the preferred embodiment of a foam material according to this invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0015] The preferred embodiment of a foamable composition according to this invention includes 100 parts by weight of a plastic material, 4 to 125 parts by weight of coal ash, and a foaming agent. [0016] Non-limiting examples of the plastic material are selected from the group consisting of polyethylene chloride, acrylate-butadiene-styrene copolymer, polystyrene, polyethylene, and combinations thereof. Preferably, the plastic material is polyethylene. The amount of the plastic material used in the foamable composition can be varied and adjusted by skilled artisans based on the type of the end products to be made from the foamable composition. When the plastic material is excessively used in the foamable composition, the purpose of reducing pollution cannot be achieved, and adverse effects on the additives can be serious. On the other hand, if the amount of the plastic material is insufficient, the coal ash cannot be completely encapsulated by the plastic material. As a result, the end products thus formed will have a coarse outer surface, and the coal ash may be easily and undesirably removed. [0017] The coal ash used in this invention may come from any suitable source. A non-limiting example of the coal ash is bottom ash, which is a sand-like material obtained from a bottom of a coal combustion furnace of a fuel electric plant. In addition, there is no specific limitation imposed on the size of the coal ash, as long as the size of the coal ash is adequate to make the outer surface of the end product as smooth as possible. In addition, there is no specific limitation imposed on the amount of the coal ash. However, an excess amount of the coal ash can result in a coarse outer surface for the end product. On the other hand, if the amount of the coal ash is insufficient, the purpose of environmental protection cannot be achieved. Preferably, the amount of the coal ash ranges from 90 to 105 parts by weight, based on 100 parts by weight of the plastic material. Preferably, the coal ash has a mesh size less than 400 mesh. More preferably, the coal ash has a mesh size less than 500 mesh, and most preferably, the coal ash has a mesh size ranging from 500 mesh to 1-000 mesh. [0018] The foaming agent can be any known foaming agent suitable for foaming reaction of plastic materials. Preferably, the foaming agent is an azoic foaming agent. More preferably, the foaming agent is azodicarbonamide. There is no specific limitation imposed on the amount of the foaming agent. However, an excess amount of the foaming agent can result in poor flexibility of the final product. On the other hand, if the amount of the foaming agent is insufficient, the specific gravity of the end product increases, and a lightweight product cannot be achieved. Preferably, the foaming agent is present in an a mount ranging from 0.75 to 1.25 parts by weight, based on 100 parts by weight of the plastic material. [0019] Preferably, the foamable composition further includes a stabilizing agent in an amount ranging from 0.5 to 1.75 parts by weight, based on 100 parts by weight of the plastic material. More preferably, the stabilizing agent is in an amount ranging from 1.0 to 1.50 parts by weight. There is no specific limitation imposed on the amount of the stabilizing agent. However, an excess amount of the stabilizing agent can result in high production cost and undesired deformation of the end product. The stabilizing agent can be any known stabilizing agent useful for preventing dissociation of the plastic material. More preferably, the stabilizing agent is alkyl tin mercaptide, and most preferably, the stabilizing agent is dimethyl tin mercaptide. [0020] Preferably, the foamable composition further includes a lubricant in an amount ranging from 0.75 to 1.25 parts by weight, based on 100 parts by weight of the plastic material. There is no specific limitation imposed on the amount of the lubricant. However, an excess amount of the lubricant has an adverse effect on foaming efficiency of the foaming agent. More preferably, the lubricant is selected from the group consisting of calcium stearate and zinc stearate. Continue reading... Full patent description for Foamable composition and method for making a foam material therefrom, and an architectural material made from the foam material Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Foamable composition and method for making a foam material therefrom, and an architectural material made from the foam material patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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